US4385135A - Intumescent sheet material containing low density fillers - Google Patents
Intumescent sheet material containing low density fillers Download PDFInfo
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- US4385135A US4385135A US06/382,156 US38215682A US4385135A US 4385135 A US4385135 A US 4385135A US 38215682 A US38215682 A US 38215682A US 4385135 A US4385135 A US 4385135A
- Authority
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- United States
- Prior art keywords
- low density
- weight
- sheet
- intumescent sheet
- density
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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- 239000000945 filler Substances 0.000 title claims abstract description 14
- 239000000463 material Substances 0.000 title abstract description 46
- 239000000919 ceramic Substances 0.000 claims abstract description 32
- 239000010455 vermiculite Substances 0.000 claims description 20
- 229910052902 vermiculite Inorganic materials 0.000 claims description 20
- 235000019354 vermiculite Nutrition 0.000 claims description 19
- 239000000835 fiber Substances 0.000 claims description 15
- 229920000126 latex Polymers 0.000 claims description 13
- 230000003197 catalytic effect Effects 0.000 claims description 12
- 239000011521 glass Substances 0.000 claims description 12
- 239000011230 binding agent Substances 0.000 claims description 9
- 239000004816 latex Substances 0.000 claims description 9
- 229910052751 metal Inorganic materials 0.000 claims description 9
- 239000002184 metal Substances 0.000 claims description 9
- 239000002657 fibrous material Substances 0.000 claims description 5
- 239000004005 microsphere Substances 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 3
- 238000005336 cracking Methods 0.000 abstract description 9
- 239000002002 slurry Substances 0.000 description 13
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 10
- 238000000034 method Methods 0.000 description 7
- 239000011256 inorganic filler Substances 0.000 description 6
- 229910003475 inorganic filler Inorganic materials 0.000 description 6
- 239000000203 mixture Substances 0.000 description 6
- 238000012856 packing Methods 0.000 description 5
- 238000010791 quenching Methods 0.000 description 5
- 239000000758 substrate Substances 0.000 description 5
- 239000010425 asbestos Substances 0.000 description 4
- 239000002131 composite material Substances 0.000 description 4
- 230000006378 damage Effects 0.000 description 4
- 229910052895 riebeckite Inorganic materials 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- 229920013646 Hycar Polymers 0.000 description 3
- 239000003054 catalyst Substances 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 230000000171 quenching effect Effects 0.000 description 3
- 230000035939 shock Effects 0.000 description 3
- 230000004083 survival effect Effects 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 229940037003 alum Drugs 0.000 description 2
- 229910000329 aluminium sulfate Inorganic materials 0.000 description 2
- 235000011128 aluminium sulphate Nutrition 0.000 description 2
- 239000008394 flocculating agent Substances 0.000 description 2
- 238000005189 flocculation Methods 0.000 description 2
- 230000016615 flocculation Effects 0.000 description 2
- 239000010881 fly ash Substances 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 244000043261 Hevea brasiliensis Species 0.000 description 1
- 239000005909 Kieselgur Substances 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 1
- 229920000459 Nitrile rubber Polymers 0.000 description 1
- 239000002174 Styrene-butadiene Substances 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- -1 alum Substances 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 description 1
- 229910052612 amphibole Inorganic materials 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- NTXGQCSETZTARF-UHFFFAOYSA-N buta-1,3-diene;prop-2-enenitrile Chemical compound C=CC=C.C=CC#N NTXGQCSETZTARF-UHFFFAOYSA-N 0.000 description 1
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 229910052620 chrysotile Inorganic materials 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 239000003792 electrolyte Substances 0.000 description 1
- 238000004299 exfoliation Methods 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 239000000383 hazardous chemical Substances 0.000 description 1
- 231100000206 health hazard Toxicity 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 229920003052 natural elastomer Polymers 0.000 description 1
- 229920001194 natural rubber Polymers 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000011115 styrene butadiene Substances 0.000 description 1
- 229920003048 styrene butadiene rubber Polymers 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 238000005382 thermal cycling Methods 0.000 description 1
- WSNJABVSHLCCOX-UHFFFAOYSA-J trilithium;trimagnesium;trisodium;dioxido(oxo)silane;tetrafluoride Chemical compound [Li+].[Li+].[Li+].[F-].[F-].[F-].[F-].[Na+].[Na+].[Na+].[Mg+2].[Mg+2].[Mg+2].[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O WSNJABVSHLCCOX-UHFFFAOYSA-J 0.000 description 1
- CWBIFDGMOSWLRQ-UHFFFAOYSA-N trimagnesium;hydroxy(trioxido)silane;hydrate Chemical compound O.[Mg+2].[Mg+2].[Mg+2].O[Si]([O-])([O-])[O-].O[Si]([O-])([O-])[O-] CWBIFDGMOSWLRQ-UHFFFAOYSA-N 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/50—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by form
- D21H21/52—Additives of definite length or shape
- D21H21/54—Additives of definite length or shape being spherical, e.g. microcapsules, beads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
- B01D53/86—Catalytic processes
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/36—Inorganic fibres or flakes
- D21H13/38—Inorganic fibres or flakes siliceous
- D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/36—Inorganic fibres or flakes
- D21H13/38—Inorganic fibres or flakes siliceous
- D21H13/44—Flakes, e.g. mica, vermiculite
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/63—Inorganic compounds
- D21H17/67—Water-insoluble compounds, e.g. fillers, pigments
- D21H17/68—Water-insoluble compounds, e.g. fillers, pigments siliceous, e.g. clays
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
- F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
- F01N3/2857—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing the mats or gaskets being at least partially made of intumescent material, e.g. unexpanded vermiculite
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
- F02B3/00—Engines characterised by air compression and subsequent fuel addition
- F02B3/06—Engines characterised by air compression and subsequent fuel addition with compression ignition
Definitions
- the present invention relates to flexible intumescent sheet materials containing low density filler components resulting in sheet materials of significantly lower density than conventionally available sheets.
- the low density sheet materials of the invention are particularly useful as a packing material for mounting and positioning automobile catalytic converter monoliths within containers and find particular utility in mounting fragile ceramic monoliths of diesel particulate filters.
- Ceramic bodies tend to be frangible and to have coefficients of thermal expansion differing markedly from those of metal containers.
- the mounting of the ceramic body in the container must provide resistance to mechanical shock due to impact and vibration and to thermal shock due to thermal cycling. Both thermal and mechanical shock may cause deterioration of the ceramic support which, once started, quickly accelerates and ultimately renders the device useless.
- Materials that have been found useful as a packing material for these purposes are disclosed in U.S. Pat. Nos. 3,916,057, 4,305,992, and U.K. Pat. No. 1,513,808.
- Sheet materials containing low density inorganic filler components may be formed by papermaking techniques as will be described more fully hereinbelow.
- the low density inorganic filler components in the form of hollow glass microspheres (glass microbubbles), fly ash or expanded vermiculite are selected in a size range to accommodate the voids and the packing characteristics of the fiber matrix which retains the filler components within the sheet.
- the preferred size of low density filler components, for optimum retention within the fiber matrix is 25 to 200 microns diameter at 10-40 weight percent loadings.
- Other inorganic fillers whose shape and size allow a significant increase in the bulk volume and, therefore, a significant decrease in the bulk density of an intumescent sheet include mica platelets and diatomaceous earth.
- the sheet material can be produced to desired thicknesses from about 0.5 to about 10 mm.
- Suitable binders can include various polymers and elastomers in latex form, as for example, natural rubber latices, styrene-butadiene latices, butadiene-acrylonitrile latices, latices of acrylate and methacrylate polymers and copolymers and the like.
- Suitable inorganic binders may include tetrasilicic fluorine mica in either the water-swelling unexchanged form or after flocculation as the exchanged salt with a di- or polyvalent cation as well as bentonite or fibrous materials such as asbestos.
- Organic and inorganic binders may be used in combination to produce sheet materials according to the present invention.
- the flexible intumescent sheet material is utilized in automobile exhaust catalytic converters as a mounting material by expansion in situ.
- the expanded sheet then holds the ceramic core or catalyst support in place in the container or canister.
- the thermal stability and resilience of the sheet after exfoliation compensate for the difference in thermal expansion of the metal canister and the ceramic substrate, for vibration transmitted to the fragile device and for irregularities in the metallic or ceramic surfaces.
- the sheet material may be formed by standard papermaking techniques, either on a handsheet former or on Fourdrinier or Rotoformer type paper machines, taking suitable precautions to attain substantially uniform distribution of particles throughout the web.
- intumescent material unexpanded treated flakes of vermiculite ore in particle sizes of from about 0.1 up to about 6 mm. and preferably up to about 2 mm., are combined in a large volume of water with solids in the proportions 10 to 50% inorganic fibrous materials, such as chrysotile or amphibole asbestos, soft glass fibers such as available under the tradename chopped E.
- refractory filaments including zirconia-silica fibers, crystalline alumina whiskers and alumina-silicate fibers (available commercially under the tradenames Fiberfrax, Cerafiber and Kaowool), 10 to 40% inorganic low density filler components such as hollow glass microspheres (B23/500 3M Glass Bubbles), fly ash or expanded vermiculite (#5 Grade from W. R. Grace Co.) and 3 to 30% of binder as described above.
- Flocculation is conveniently achieved using electrolytes such as alum, alkali or acid.
- Small amounts of organic fibrous materials may be added to impart additional green strength to the green sheet material.
- the intumescent material, inorganic fibrous material, low density inorganic filler component and organic latex binder are blended together in a large volume of water, of the order of 5 to 100 times as much by weight and the flocculating agent or agents are added.
- a small amount of surfactant or foaming agent may also be employed in order to improve the dispersion of the intumescent material without going beyond the scope of the invention.
- asbestos fibers are less expensive than other fibers.
- vermiculite ore refers to unexpanded vermiculite.
- alumina-silicate fibers J-M Cerafibers
- the fiber slurry is transferred to a 4 liter beaker and mixed with an air propelled blade.
- 8.0 gms of B. F. Goodrich Hycar 1562 X103 latex binder, and 29.8 gms of #4 Grade vermiculite ore (W. R. Grace Co.) are added to the fiber slurry.
- 8 ml of dilute papermakers alum (25% solution of aluminum sulfate) is added to the slurry to precipitate the latex binder onto and/or dispersed throughout the other components.
- the mixture is agitated vigorously and then quickly poured onto a handsheet screen and allowed to set momentarily so as to minimize the pouring turbulence before tripping the drain to dewater. Drain time is about 5 seconds.
- the top sheet surface is blotted, the formed sheet is removed and sandwiched between additional blotters for pressing at 0.003 N/mm 2 .
- the wet sheet is further dried on a conventional Williams Apparatus Co. sheet drier.
- the resulting intumescent sheet composite is exemplary of the state-of-the-art intumescent sheet materials described in U.S. Pat. Nos. 3,916,057 and 4,305,992.
- Alumina-silicate fibers (J-M Cerafibers) were slushed at 1.5% solids in a 2500 gallon Morden Slush-Maker for 4.0 minutes.
- the fiber slurry was pumped to a 3000 gallon stock chest in which 135 lbs. Hycar 1562 X103 latex (41% solids) was added.
- the latex was precipated with papermakers alum to a pH of 4.9.
- 80 lbs. of B23/500 3M Glass Bubbles (80 microns average diameter) were added to the latex-fiber slurry and then metered to the wet end at controlled flow rates.
- #4 Grade vermiculite ore (W. R.
- Example 1 The latex-fiber-microbubble-vermiculite ore slurry was then pumped to the headbox of a Rotoformer paper machine to form and dewater a composite sheet 52 inches wide. The dewatered sheet was then wet pressed at 0.06 N, dried, and wound up into jumbo rolls at the dry end of the paper machine. The machine speed was changed three times to produce three different basis weight low density mat materials. Sheet properties were as follows:
- J-M Cerafibers alumina- silicate fibers
- alumina- silicate fibers J-M Cerafibers
- This slurry was pumped to a 2000 gallon stock chest and diluted with an additional 530 gallons of water.
- This latex-fiber-expanded vermiculite slurry was pumped to a mixing vat at controlled flow rates. 190 4 Grade vermiculite ore (W. R. Grace Co.) was then metered and mixed with the slurry to provide a solids composition as stated in Example 1, Run 6. The slurry was then flowed onto a Fourdrinier wire to form and dewater a composite sheet 18 inches wide. The dewatered sheet was then wet presed at about 0.06N, dried, and wound up into rolls at the dry end of the paper machine. The machine speed was changed five times to produce five different basis weight low density mat materials with the following sheet properties:
- A. "Green” push out force This is the force required to move the ceramic core and is a function of the force exerted on the ceramic core by the intumescent sheet just after mounting of the converter assembly and measures the "looseness” or “tightness” of the core before heating or intumescence of the sheet material.
- a "loose” mount is unacceptable since damage to the ceramic core can easily occur in the normal handling and initial operation of the catalytic converter.
- a hot vibration and water quenching test of converter mounting systems is used by automotive companies to simulate 50,000 miles of actual use on automobiles. This test consists of wrapping an oval substrate (8.3 cm long ⁇ 12.0 cm wide ⁇ 8.0 cm high) with test intumescent mounting material and placing the wrapped substrate between two metal clamshell type canister halves in which the mounting gaps were premeasured to be between 3.75 to 5.20 mm. The canister halves are pressed together and welded to complete the converter assembly. The converter assembly is connected to the exhaust of an eight cylinder engine for 30 minutes with the exhaust temperature controlled at 600° C. The hot converter is quenched with water for 30 seconds and reheated for 30 minutes. The quenching and heat cycles are repeated 20 times.
- the converter is mounted in an Unholtz-Dickey vibrator and again connected to the eight cylinder engine exhaust controlled at 600° C. to 950° C. (the lower test temperatures can be used to simulate conditions of underbody converters while the higher test temperatures simulate converters mounted closer to the exhaust manifold).
- the test converter is then vibrated at 35 G's at 100 Hz for 30 hours. Failure of the mounting material results in movement and/or destruction of the ceramic substrate within the canister before completion of the water quenching cycles and/or vibration times stated. Survival of the system is representative of at least 50,000 miles of actual automobile use.
- mount density of mounting materials within converter assemblies is a function of the mounting gap in conjunction with the mass (weight/area) of the mounting sheet materials used. It has been shown that the holding forces of the mats vary (Example 4) with mount density, and that failure of the system can occur if the mount density is too low. The following water quench/hot vibration tests were run to establish the lower mount density limits of both standard and low density intumescent sheet materials.
- the above table shows that failures of the mounting sheet can be expected when the hot push out force on the ceramic monolith is about 1200 Newtons or less (test nos. 3 and 7). Survival of the system can be expected when the hot push out force is 1700 Newtons or greater (test nos. 1, 2, 4, and 6).
- the vibration tests of the low density microbubble intumescent sheet show failure at the 875° C. test temperature and survival at 610° C. This is due to the lower melting point of the glass microbubbles, i.e., about 610° C. It is obvious from these tests that the higher continuous use temperatures typical of the expanded vermiculite containing sheet is desired and required in most intumescent sheet converter mounting applications. It is possible however that the low density microbubble filled sheet could be used at lower temperatures such as found in catalytic converters located further from the engine.
- the second test criteria for acceptable intumescent sheet materials is found in the above table under "Green" push-out force.
- test no. 2 the state-of-the-art intumescent sheet mounted at 0.478 gm/cc density exerts more than adequate holding force to pass the vibration test but the "loose" mount in the green state is unacceptable due to potential damage to the ceramic core inside the metal housing during the handling and assembly operations in manufacturing automobiles. It has been found that unacceptable "loose” mounts will occur below about 0.6 gm/cc green mount density with the state-of-the-art intumescent sheet materials.
- the low density intumescent sheets of the present invention when formulated properly, can provide the "tightness" of fit at a much lower green mount density of 0.4 gm/cc. This reduction in mount density, of at least 33%, still provides the hot holding forces necessary to survive the vibrations inherent in the operation of automobiles.
- a test was devised to determine the maximum mount density of standard and low density intumsecent sheet materials that could be used in mounting diesel particulate filters without encountering ring off cracking.
- Diesel particulate filters (116.8 mm diameter ⁇ 152.4 mm long, 100 cells/in. 2 monoliths from Corning Glass Works) were mounted into cylindrical canisters having a mounting gap of about 3.0 mm.
- the test units were assembled at various mount densities using sheet materials from Example 1 and connected to an exhaust gas simulator (made by RPS Engineering Co.) and heated to 950° C. for ten minutes. The test unit was cooled, disassembled, and inspected for ring off cracking.
- the workable mount density range for the prior art intumescent sheet is 0.64 ⁇ 0.04 gm/cc or ⁇ 6.3%.
- the workable range for the Example 1, Run No. 6 low density intumescent sheet is 0.54 ⁇ 0.14 gm/cc or ⁇ 25.9%.
- the low density intumescent sheets of the present invention provide a workable converter mount density range about four times greater than the range provided by currently available state-of-the-art intumescent sheets.
Abstract
Description
__________________________________________________________________________ Example 1, Run 1 2 3 4 5 6 7 8 9 10 __________________________________________________________________________ Hycar 1562 ×103 (wt. %) 6.8 6.8 6.8 6.8 6.8 8.2 9.4 10.6 9.1 8.0 Johns-Manville Cerafibers (wt. %) 31.2 31.2 31.2 31.2 31.2 37.7 43.0 48.3 41.2 36.7 Vermiculite Ore (wt. %) 62.0 52.0 42.0 52.0 42.0 30.0 20.0 10.0 10.0 20.0 B23/500 3M Glass Bubbles (wt. %) -- 10.0 20.0 -- -- -- -- -- -- -- Expanded Vermiculite (wt. %) -- -- -- 10.0 20.0 24.1 27.6 31.1 39.7 35.3 Weight/Area (Kg/m.sup.2) 1.059 1.550 1.550 1.528 1.515 1.531 1.576 .809 .794 .814 Caliper (mm) 1.74 3.40 4.61 3.82 4.63 5.43 6.18 3.24 3.48 3.20 Density (gm/cc) .609 .454 .336 .400 .327 .282 .255 .255 .228 .253 __________________________________________________________________________
______________________________________ Example 2, Run 1 2 3 ______________________________________ Average weight/area (Kg/m.sup.2) 1.10 1.37 1.63 Average thickness (mm) 2.3 2.6 3.2 Average bulk density (gm/cc) .478 .525 .508 ______________________________________
______________________________________ Example 2, Run 4 5 ______________________________________ Average weight/area (Kg/m.sup.2) 1.45 1.00 Average thickness (mm) 2.3 1.6 Average bulk density (gm/cc) .630 .625 ______________________________________
______________________________________ Example 3, Run 1 2 3 4 5 ______________________________________ Average weight/area (Kg/m.sup.2) 1.357 1.292 1.203 1.087 0.970 Average thickness (mm) 3.25 3.05 2.88 2.94 2.40 Average bulk density (gm/cc) .418 .424 .417 .370 .405 ______________________________________
______________________________________ Converter Mount Push Out Force Example 1, Low Density Density (Newtons) Run No. Filler Component (gm/cc) Green Hot ______________________________________ 1 None .404 "Loose" 1175 1 None .485 "Loose" 4950 1 None .656 10 10600 2 10% Bubbles .486 50 3550 3 20% Bubbles .495 175 7000 4 10% Exp. Verm. .478 25 4600 5 20% Exp. Verm. .478 75 5675 6 24.1% Exp. Verm. .317 10 1121 6 24.1% Exp. Verm. .402 10 1700 6 24.1% Exp. Verm. .468 175 6325 7 27.6% Exp. Verm. .324 25 1975 7 27.6% Exp. Verm. .500 250 7725 8 31% Exp. Verm. .311 500 825 9 39.7% Exp. Verm. .306 750 1750 10 35.3% Exp. Verm. .314 600 1785 ______________________________________
__________________________________________________________________________ Converter Vibration Mounting Test Vibration Test Example 1, Low Density Density Temp. Test Push-Out Force (N) No. Run No. Filler (gm/cc) (°C.) Results Green @ 600° C. __________________________________________________________________________ 1 1 None .657 875 30 hr pass 10 10600 2 1 None .478 875 30 hr pass "Loose" 4950 3 1 None .404 875 1 min fail "Loose" 1175 4 2 10% Bubbles .600 610 30 hr pass 300 8600 5 3 20% Bubbles .410 875 1 min fail 10 1800 6 6 24.1% Exp. Verm. .404 875 30 hr pass 10 1700 7 6 24.1% Exp. Verm. .314 875 1 min fail <10 1120 __________________________________________________________________________
______________________________________ Converter Mount Example 1, Low Density Density Run No. Filler Component (gm/cc) Ring-Off-Crack ______________________________________ 1 None .667 No 1 None .705 yes 2 10% Bubbles .608 No 6 24.1% Exp. Verm. .681 No 6 24.1% Exp. Verm. .708 Yes ______________________________________
______________________________________ Intumescent Sheet Converter Mount Density Limits Material Lower (gm/cc) Upper (gm/cc) ______________________________________ State-of-the-art 0.60 0.68 Example 1, Run No. 6 0.40 0.68 ______________________________________
Claims (5)
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US06/382,156 US4385135A (en) | 1982-05-26 | 1982-05-26 | Intumescent sheet material containing low density fillers |
EP83302793A EP0095308B1 (en) | 1982-05-26 | 1983-05-17 | Intumescent sheet material containing low density fillers |
DE8383302793T DE3366721D1 (en) | 1982-05-26 | 1983-05-17 | Intumescent sheet material containing low density fillers |
CA000428713A CA1176451A (en) | 1982-05-26 | 1983-05-24 | Intumescent sheet material containing low density fillers |
AU14962/83A AU560556B2 (en) | 1982-05-26 | 1983-05-25 | Intumescent sheet materials |
JP58092215A JPS58213691A (en) | 1982-05-26 | 1983-05-25 | Swellable sheet material containing low density filler |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US06/382,156 US4385135A (en) | 1982-05-26 | 1982-05-26 | Intumescent sheet material containing low density fillers |
Publications (1)
Publication Number | Publication Date |
---|---|
US4385135A true US4385135A (en) | 1983-05-24 |
Family
ID=23507749
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US06/382,156 Expired - Lifetime US4385135A (en) | 1982-05-26 | 1982-05-26 | Intumescent sheet material containing low density fillers |
Country Status (6)
Country | Link |
---|---|
US (1) | US4385135A (en) |
EP (1) | EP0095308B1 (en) |
JP (1) | JPS58213691A (en) |
AU (1) | AU560556B2 (en) |
CA (1) | CA1176451A (en) |
DE (1) | DE3366721D1 (en) |
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US5705444A (en) * | 1996-05-06 | 1998-01-06 | Minnesota Mining & Manufacturing Company | Filter material of ceramic oxide fibers and vermiculite particles |
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WO1980001576A1 (en) * | 1979-02-05 | 1980-08-07 | Hollingsworth & Vose Co | Sheet material containing exfoliated vermiculite |
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- 1982-05-26 US US06/382,156 patent/US4385135A/en not_active Expired - Lifetime
-
1983
- 1983-05-17 EP EP83302793A patent/EP0095308B1/en not_active Expired
- 1983-05-17 DE DE8383302793T patent/DE3366721D1/en not_active Expired
- 1983-05-24 CA CA000428713A patent/CA1176451A/en not_active Expired
- 1983-05-25 JP JP58092215A patent/JPS58213691A/en active Granted
- 1983-05-25 AU AU14962/83A patent/AU560556B2/en not_active Ceased
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FR23420E (en) * | 1920-08-12 | 1921-11-16 | Siemens Schuckertwerke Gmbh | Solenoid coil |
US2884380A (en) * | 1956-08-23 | 1959-04-28 | Carey Philip Mfg Co | Thermal insulation material and method of making the same |
JPS5180323A (en) * | 1975-01-08 | 1976-07-13 | Haneda Concrete Kogyo | GARASUFUAIBAAKYOKAKONKURIITOKANNO SEIZOHOHO |
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Also Published As
Publication number | Publication date |
---|---|
CA1176451A (en) | 1984-10-23 |
EP0095308B1 (en) | 1986-10-08 |
JPH0124750B2 (en) | 1989-05-12 |
DE3366721D1 (en) | 1986-11-13 |
JPS58213691A (en) | 1983-12-12 |
EP0095308A1 (en) | 1983-11-30 |
AU1496283A (en) | 1983-12-01 |
AU560556B2 (en) | 1987-04-09 |
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